Pallet-clad Espresso Cart

This Pallet-Clad Espresso Cart only cost about 100 dollars! Made from mostly repurposed materials and clad in angle-steel, this cart could be in the most expensive of espresso and coffee shops – or your kitchen!

How I made this Pallet-Clad Espresso Cart:

First, I framed the main box out from repurposed 2x4 boards. It is basically like framing out a chest, but then roll the chest up on one side, and you’d have this cart. The main body of it is wide-open to accommodate a small refrigerator and a five-gal water bottle or two, with clearance for whatever sink you choose to install. I installed heavy-duty locking casters. I finished the frame out by flooring it with long deck boards.

Next, the sides were clad with pallet wood. I used all pine pieces for a consistent look and stain properties. I staggered the joints so it would look nicer, and didn’t mind a bit of warping – that’s what makes working with pallets fun, after all!

Pallet-Clad Espresso Cart - the top:

Editor’s note: It appears that some type of backer board (such as particle board, drywall, or cement backer board) was used as a substrate material for the countertops. Then, possibly a laminate top of some kind was applied. The information was not provided by the crafter.

FYI: If you apply to wood or another laminate top to a surface (such as a countertop), the recommended substrate is usually particle board, but follow the laminate top manufacturer's guidelines. This is due to expansion/contraction rates of the substrates in comparison to the glues.

Pallet-Clad Espresso Cart – Making it Heavy Metal:

The final decorative touches included adding upcycled 2x2” angled steel brackets. I dry fit them first, then installed them in place with screws and decorative trim washers. Then I used an angle grinder to remove most of the surface rust, discoloration, and imperfections. Next, I welded all the angle joints. I used the angle grinder again and cleaned up the welds. I continued to grind and polish the metal until only small amounts of the gray oxidization remained, but most was ground somewhat shiny. I purposely left a lot of the grind marks – they look cool!

The finishing touches were to stain the wood laminate top and the sides a beautiful cherry color and then to install the equipment. I installed an espresso machine and a chrome handle. I sealed everything with a polyurethane coating.

With an estimated 2 billion pallets being used every day, and many more sitting around, no wonder so many projects have been done using pallets. Here are 1001 ways to recycle, upcycle, reuse or repurpose pallets! If you are a pallet upcycler, do not hesitate to send us your work, we will be happy to showcase it to the world!

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